Steam trapping overview * s t e a m t r a p p i n g Make your steam system safe, efficient and sustainable The duty of a steam trap is to discharge condensate while retaining live steam in the system. This ensures your steam system is able to operate efficiently, without the detrimental effects of unwanted condensate essential in temperature critical applications. Condensate in the system can lead to a number of issues such as: - Poor heat transfer - Damage to system and process equipment - Poor quality or wasted product Selecting the right steam trapping solution helps to avoid these problems, whilst at the same time allowing the condensate to be recovered. Information on the significant benefits of recovering condensate can be found at the back of this brochure. How can Spirax Sarco help you? We’ve been in the business of steam solutions for over 100 years and with our exceptional team of specialists, we take the time to understand your needs and work with you to find the most effective steam trapping solutions for your applications. Our aim is to help you meet your sustainability and efficiency goals by ensuring your steam system operates at its optimum level at all times. Effective steam trapping is a key factor in achieving this objective. spiraxsarco.com 3 An introduction to steam traps Each steam application has its own steam trap requirements. Selecting the right steam trap for your application could have a significant, positive impact on your process, potentially improving efficiency, reducing energy costs and giving you a safer working environment. For example: condensate must be removed promptly from a plant where maximum heat transfer is sought at all times. The presence of excess condensate in an item of heat transfer equipment will reduce its efficiency, preventing it from achieving its maximum rated output and may also reduce its service life. However; in other applications, it may be required to hold back the condensate to extract some of its heat and thus save on steam. Furthermore, by discharging condensate well below steam temperature, flash steam losses can be reduced or avoided altogether. Thermodynamic steam traps Maintaining optimum process performance Thermodynamic steam traps are the best choice for steam mains drainage due to their simplicity, long life and robust construction. With a large condensate capacity for their size, the all stainless steel construction of our thermodynamic traps offer a high degree of resistance to corrosive condensate. Mechanical steam traps Maintaining optimum process performance Mechanical steam traps are ideal for use on process applications where condensate must be removed as soon as it forms, to safeguard against temperature fluctuation which would lead to issues such as product spoilage and inadequate heating. Our mechanical steam trap range is adaptable to all applications where instantaneous removal of condensate is required. Thermostatic steam traps Utilising heat energy in condensate For applications where it would be desirable to make use of the heat in the condensate such as sterilisation, a thermostatic steam trap is an ideal solution as it will not open until the condensate temperature drops below saturated steam temperature. This allows the heat in the condensate to be utilised before it is drained off which in turn reduces flash steam losses and can help to reduce energy costs. Spirax Sarco offers a complete range of steam traps to ensure you can select the perfect trap for your application. s t e a m t r a p p i n g Spirax Sarco’s steam trap range Steam trap operation Thermodynamic Thermodynamic Mechanical Ball float Inverted bucket Thermostatic Balanced pressure Bimetallic Steam trap types Main features • Robust design giving excellent resistance to waterhammer and vibration • High capacity • Inexpensive • Continuous discharge of condensate for maximum heat transfer • Positive discharge with tight shut-off • Discharge condensate close to steam saturation temperature Mains drainage and all tracing applications. Typical applications Size Maximum body rating Maximum operating pressure • Excellent air venting capabilities • Will not back-up with condensate • High capacity • Robust design • Near continuous discharge of condensate • Minimal back-up of condensate • Utilises sensible heat in the condensate, reducing flash steam losses, which saves energy • Excellent air venting properties for quick start-up Temperature / pressure controlled applications with fluctuating loads Temperature / pressure controlled applications with fluctuating loads DN8 – DN25 (¼”– 1”) DN15 – DN100 (½" – 4") DN15 – DN50 (½" – 2") DN8 – DN25 (¼"– 1") DN8 – DN100 (¼"– 4") PN250 PN100 and ASME Class 600 ASME 900 PN40 and ASME Class 300 PN420 and ASME Class 2500 250 bar g 80 bar g 110 bar g 32 bar g 210 bar g Some process applications with light loads such as small presses and cylinders • Where condensate back-up can be tolerated or is required in order to remove excess enthalpy, e.g. non-critical tracing 5 t h e r m o d y n a m i c s t e a m t r a p s Thermodynamic steam traps How a thermodynamic steam trap works 1 2 3 4 1. On start-up, incoming pressure raises the disc and cooled condensate, and air is immediately discharged. 2. Hot condensate flowing through the trap releases flash steam. High velocity creates a low pressure area under the disc and draws it towards the seat. 3. At the same time there is a pressure build-up of flash steam in the chamber above the disc which forces it down against the pressure of the incoming condensate until it seats on the inner ring and closes the inlet. The disc also seats on the outer ring and traps pressure in the chamber. 4. Pressure in the chamber is decreased by condensation of the flash steam and the disc is raised. The cycle is then repeated. Features and benefits: • Positive condensate discharge with clean tight shut-off • Discharges condensate at very close to steam temperature that ensures maximum plant efficiency • Just one moving part, a disc, ensures reliable operation and minimal maintenance without having to remove from the line • Compact and light weight, reducing installation costs • Hardened disc and seat for long life • One trap covers a wide range of operating pressures making selection and replacement simple • Insulating cover for low ambient temperature or wet environments • Thermodynamic traps can be used on high pressure and superheated steam and are not affected by waterhammer or vibration. spiraxsarco.com Thermodynamic steam traps - product range Material Sizes Maximum operating pressure Connection 42 bar g Socket weld TD42S2 TD42S2LC Horizontal 46 bar g Screwed Socket weld Flanged TDC46M Horizontal 10 bar g Screwed 30 bar g Swivel UTD30L UTD30H (universal connection) Universal 32 bar g Flanged TD32F TD32FLC Horizontal Horizontal Carbon steel DN8 ¼" 42 bar g Screwed DN20 ¾" DN25 1" TD 259 TD52M Recommended installation Horizontal TD3-3 TD3-3 TD3-3LC TD3-3 TD42LC TD42L TD52M TD42 TD42LC TD42H TD42L TD52M TD52MLC TD42 TD42H TD42L TD52M Horizontal Swivel 46 bar g Screwed Socket weld Flanged TDS46M Horizontal 62 bar g Screwed Socket weld Flanged TD62M TD62LM Horizontal 250 bar g Socket weld Butt weld Flanged TD120M Horizontal Screwed UTDS46M TD42H TD42L TD52M 46 bar g Alloy steel Stainless steel (Clean steam) DN15 ½" TD10 Butt weld Stainless steel DN10 " BTD52L Universal Horizontal 10 bar g Clamp Tube end BTD52L Horizontal 7 m e c h a n i c a l s t e a m t r a p s Mechanical steam traps Ball float mechanical steam traps Ball float (FT) mechanical steam traps have an integral air vent as standard and the options of a manually adjustable needle valve (SLR - steam lock release mechanism) and drain cock tapping, the FT range is adaptable to all applications where ball float traps are recommended and instantaneous removal of condensate is required. How a ball float steam trap works 1. On start-up a thermostatic air vent allows air to bypass the main valve (1) which would otherwise be unable to escape (a condition known as ‘air-binding’). 1 2 3 4 2. As soon as condensate reaches the trap, the float is raised and the lever mechanism opens the main valve. Hot condensate closes the air vent but continues to flow through the main valve. 3. When steam arrives the float drops and closes off the main valve, which remains at all times below the water level, ensuring that live steam cannot be passed. 4. As the steam condenses, the float rises allowing condensate to be released. Features and benefits: • Immediate condensate discharge with clean, tight shut-off. No backup of condensate ensures maximum plant efficiency • Works efficiently on both heavy and light loads with no passage of live steam • Not affected by wide and sudden fluctuations of pressure or flowrate • Stainless steel internals that can tolerate corrosive condensate • Integral air vent to ensure rapid warm-up of plant • Robust construction to guarantee long life against waterhammer and vibration. spiraxsarco.com Ball float steam traps - product range Material Maximum operating Connection DN15 ½" pressure 13 bar g Sizes DN20 ¾" DN25 1" DN40 1½" DN50 2" DN80 3" DN100 4" Installation FT43 FT43 FT53 FT43V FT43V FT53V Vertical down FT14 Horizontal Flanged Cast iron 14 bar g DN32 1¼" Screwed FT43 Horizontal FT14 Horizontal FT14V Vertical down FT14 Horizontal Screwed 14 bar g Flanged SG iron 21 bar g Screwed FT47 FT57 Horizontal Flanged FT47V FT57V FT47V FT57V Vertical down Screwed FTGS14 Horizontal Flanged FTGS14 Horizontal 14.6 bar g 17 bar g Screwed 23 bar g Flanged 32 bar g Flanged Stainless steel Stainless steel (Clean steam) Horizontal FT47 FT57 Screwed Socket weld Carbon steel FT14 Flanged 32 bar g ENP coated SG iron cover and stainless steel body FT14HC FTGS14HC Horizontal FTC23 FTC32 Horizontal FT450* FTC32V Horizontal Vertical down FTC32 FT44 FT54 FTC32V FT44V FT54V FT44 FT54 FT44 FT54 FT44 FT450* FT44V FT54V FT44V FT54V Vertical down Horizontal 80 bar g Socket weld Flanged FTC80 Horizontal 23 bar g Flanged FTS23 Horizontal Screwed Socket weld Flanged FTS14 Horizontal 19 bar g FTS14V Vertical down 25.5 bar g Flanged FT46 32 bar g Swivel UFT32 Universal FTS14-4.5 Horizontal 4.5 bar ΔP Clamp FTS14V-4.5 Vertical down * not PED approved FT46 Horizontal 9 m e c h a n i c a l s t e a m t r a p s Mechanical steam traps Inverted bucket mechanical steam traps Our inverted bucket steam traps employ a well-proven principle which relies on the difference in density between steam (a vapour) and condensate (a liquid). They have a robust design and incorporate a simple density sensitive bucket and lever mechanism. How an inverted bucket steam trap works 1 2 3 4 1. As condensate reaches the trap it forms a waterseal inside the body. The weight of the bucket keeps the valve off its seat. Condensate can then flow around the bottom of the bucket and out of the trap. 2. When steam enters the underside of the bucket it gives it buoyancy and the bucket rises. This positions the lever mechanism such that the main valve ‘snaps’ shut due to flow forces. 3. The bucket will lose its buoyancy as the enclosed steam condenses due to radiation losses and steam escapes through the vent hole. Once this happens the weight of the bucket will pull the valve off its seat and the cycle is then repeated. 4. Any air reaching the trap will also give the bucket buoyancy and close the valve preventing condensate flow. The small vent hole positioned at the top of the bucket will lead air into the top of the trap. Because the vent hole at the top of the bucket is small in diameter it will vent air very slowly. Where the venting of air may be a particular problem, this can be overcome simply by fitting an external air vent in parallel. Features and benefits: • Near continuous condensate discharge with tight shut-off. Minimal back-up of condensate ensures maximum plant efficiency • Deep water-seal to protect against the possibility of steam loss • Suitable for superheat conditions when fitted with internal inlet check valve • Simple and robust construction to guarantee long life against waterhammer and vibration • Stainless steel internals are attached to the cover for ease of maintenance • Integral strainer (HM, HM34 and SCA models only) • Optional blowdown valve (only for HM and HM34). spiraxsarco.com Inverted bucket steam traps - product range Material Cast iron Carbon steel Sizes Maximum operating pressure Connection 13 bar g Screwed Flanged 14 bar g Screwed Flanged 22 bar g Screwed Flanged 32 bar g Screwed Socket weld Flanged HM34 Horizontal 41 bar g Screwed Socket weld Flanged SCA Horizontal 116 bar g Screwed Socket weld Flanged DN15 ½" DN20 ¾" DN25 1" DN40 1½" S SF DN50 2" DN80 3" Installation Horizontal HM Horizontal 200 IBV Series C IBV Series C-LDF2 Vertical Vertical Screwed Socket weld Flanged SIB30 SIB30H Horizontal Swivel UIB30 UIB30H Universal 60 bar g Screwed Flanged SIB45 Horizontal 63 bar g Swivel UIB46 Universal 123 bar g Screwed Socket weld Flanged 30 bar g Stainless steel Alloy steel IBV Series Z Vertical 11 t h e r m o s t a t i c s t e a m t r a p s Thermostatic steam traps 1 How a balanced pressure thermostatic steam trap works 1. On start-up, cold air and condensate enter the trap. As the capsule is also cold, the valve is open and the air and condensate are discharged. 2. The capsule warms up as the condensate approaches steam temperature. Its liquid filling boils, and the resultant vapour pressure acting on the diaphragm pushes the valve head towards the seat, fully closing at the selected discharge temperature before any steam is lost. 2 3. As the condensate within the trap cools, the vapour filling condenses and the internal capsule pressure falls. The valve reopens, discharges condensate and the cycle repeats. Features and benefits: • Condensate is discharged at below steam saturation temperature, utilising sensible heat in the condensate and reducing flash steam losses • Automatically discharges air and other incondensable gases to aid rapid warm-up of plant • It automatically adjusts itself to variations of steam pressure up to its maximum operating pressure and can tolerate superheat up to 70°C • Discharge temperature set by capsule selection – no requirement to adjust on site • Manufactured using advanced technology to exacting quality standards • All stainless steel internals extend working life and reduce plant maintenance • The BPC32 and BPS32 series has a two bolt cover design for ease of maintenance. 3 spiraxsarco.com Balanced pressure thermostatic steam traps - product range Material Brass Maximum operating pressure 13 bar g Sizes Connection DN8 ¼" DN10 " DN15 ½" DN20 ¾" DN25 1" DN40 1½" Recommended installation BPT13S BPT13US Horizontal BPT13A BPT13UA Angle Screwed Screwed BPM21L Horizontal 21 bar g Socket weld Carbon steel BPM21L Screwed Socket weld BPC32 BPC32Y Horizontal Flanged BPC32 BPC32F BPC32Y BPC32YF Horizontal 32 bar g Screwed 21 bar g Stainless steel 30 bar g 32 bar g 7 bar g MST21 MST21H TSS21 MST21H BPW32 Screwed Socket weld Flanged SBP30 Vertical down Vertical down Horizontal Screwed Socket weld Flanged BPS32 BPS32Y Horizontal Swivel UBP32 Universal BTM7 BTS7 Vertical down BTM7 BTS7 BTS7.1 Vertical down BTM7 BTS7 Clamp Tube end 6 bar g MST21 Sandwich between flanges Screwed Stainless steel (Clean steam) Horizontal Clamp Tube end BTM7 BTS7 Vertical down BT6-BH BT6-BL Vertical down 13 t h e r m o s t a t i c s t e a m t r a p s Thermostatic steam traps 1 How a bimetallic thermostatic steam trap works 1. On start-up, the bimetallic element is relaxed and the valve is open. Cooled condensate, plus air, is immediately discharged. 2. Hot condensate flowing through the trap heats the bimetallic element causing it to pull the valve towards the seat. 3. As the hot condensate is discharged and approaches steam saturation temperature the bimetallic element closes the valve. When there is no flow through the trap the condensate surrounding the element cools causing it to relax and the upstream pressure opens the valve. Condensate is discharged and the cycle repeats. Features and benefits: • Condensate is discharged at below steam saturation temperature, utilising sensible heat in the condensate and reducing flash steam losses • Automatically discharges air and other incondensable gases to aid rapid warm-up of plant • The bimetal elements can work over a wide range of steam pressures without any need for on-site adjustment • Resistant to waterhammer and freezing • The SMC32 series has a two bolt cover design for ease. 2 3 spiraxsarco.com Bimetallic thermostatic steam traps - product range Material Sizes Maximum operating pressure Connection 21 bar g Socket weld Butt weld Flanged DN8 ¼" DN10 " DN20 DN25 ¾" 1" DN40 1½" DN50 DN80 2" 3" DN100 4" SP80 SP100 Recommended installation Horizontal Screwed Socket weld Butt weld SMC32 SMC32Y Horizontal Flanged SMC32 SMC32F SMC32Y SMC32YF Horizontal 32 bar g Carbon steel DN15 ½" 40 bar g Screwed Socket weld Flanged 45 bar g Screwed Socket weld Butt weld Flanged 17 bar g Screwed 21 bar g Swivel USM21 Universal Swivel USM32 Universal Screwed Socket weld Flanged PBX Horizontal ABL HP45 T3 Horizontal Horizontal Vertical down Stainless steel 32 bar g 45 bar g Screwed Socket weld Butt weld Flanged 80 bar g Alloy steel 100 bar g 150 bar g 210 bar g Socket weld Butt weld Flanged SM45 Horizontal HP80 Horizontal HP100 Horizontal HP150 Horizontal HP210 Horizontal 15 s t e a m t r a p p i n g Reducing production running costs Spirax Sarco can supply fabricated steam trap stations and a range of ‘quick-fit’ solutions that will allow rapid steam trap replacement and significantly reduce labour costs. Universal steam traps for use with pipeline UTD30L and UTD30H up to 30 bar g UTDS46M up to 46 bar g* Thermodynamic steam trap Thermodynamic steam trap Pipeline connectors Key features: • A simple two-bolt connector design allows quick and simple maintenance of a steam trap Reducing system downtime and maintenance costs compared to traditional trapping stations • Single permanent in-line component for ease of specification and installation • Prefabricated construction minimises on-site fabrication and the welded joints eliminate potential leak paths • All stainless steel construction for maximum system life. PC10HP up to 62 bar g* PC20 up to 32 bar g PC30 series up to 62 bar g* spiraxsarco.com connectors for a ‘quick fit’. UFT32 up to 32 bar g UIB30 / UIB30H up to 30 bar g UBP32 up to 32 bar g USM21 up to 21 bar g Ball float steam trap UIB45 up to 63 bar g* Balanced pressure steam trap USM32 up to 32 bar g Inverted bucket steam trap Bimetallic steam trap The pipeline connectors require 2 bolts for connection with a steam trap. *subject to limitation of pipeline connector Steam trapping station PC3000 series up to 62 bar g* PC40 series up to 62 bar g* PC4000 series up to 62 bar g* STS17.2 up to 17.5 bar g Steam trapping station Downstream isolation valve Upstream isolation valve Check valve Pipeline connector with an integral strainer screen * Subject to pressure limits of trap selected 17 s t e a m t r a p p i n g Steam tracing using our compact dual duty manifold Key features: • Minimises on-site fabrication and testing Steam tracing is used principally to maintain a reasonable product temperature and viscosity in order to simplify • Lower cost than conventional welded design pumping, avoid freezing, solidification and stagnation. • Shortens project lead times Although the rates of condensate are relatively small, trap • Space saving with standardised design populations will be large since all tracer lines should be individually trapped. For ease of design and layout, the • Lightweight to support and easy to install with optional mounting kit condensate from the traps is collected in a manifold. The steam to the tracers can be distributed utilising a similar • Easy to maintain manifold arrangement. • Optional insulation jacket for energy conservation. Our forged MSC series manifold minimises on-site fabrication and testing. DN Tracer connections Manifold type Number of tracer connections 15 20 BSP NPT SW MSC04 4 ● ● ● ● ● MSC08 8 ● ● ● ● MSC12 12 ● ● ● ● EN 10204 3.1.B certification Options Insulation jacket Mounting kit Standard ● ● ● Standard ● ● ● Standard ● ● Steam main Condensate main Product line To tracer lines From tracer lines MSC steam distribution manifold MSC condensate collection manifold We will advise on the best steam trap type for your requirements Typical applications for steam traps Mains drainage Vulcaniser application Condensate main Steam main Steam to jacket Steam into chamber Condensate from jacket to condensate system Condensate from chamber to waste Hot plate process Hotplates Steam in Condensate out Condensate in 19 spiraxsarco.com Turbine drainage Process equipment Steam in Steam out Condensate out Air vent Condensate Drainage of a separator Secondary flow Steam Condensate Condensate spiraxsarco.com The benefits of effective steam trapping Spirax Sarco are focused on helping our customers achieve process efficiency, increased production output and energy savings, and we know the importance of effective steam trap management in achieving this. A healthy steam trap population allows condensate to be removed from the steam system effectively which means it can be re-used. We call this ‘condensate recovery’ and it saves energy and cost in a number of different ways: Reduced fuel costs Normally, condensate will contain around 25% of the usable energy of the steam from which it came. Returning this to the boiler feedtank can save thousands of pounds per year in energy alone. Energy saving Condensate returned to the feedtank reduces the need for boiler blowdown, which is used to reduce the concentration of dissolved solids in the boiler. This therefore reduces the energy lost from the boiler during the blowdown process. Reduced water charges Returning and re-using condensate reduces the requirement for fresh replacement water. Reduced chemical treatment costs Re-using as much condensate as possible minimises the need for costly chemicals to treat raw water. Reduced effluent costs In many countries there are restrictions on releasing effluent at elevated temperatures so it must be cooled if discharged which incurs extra costs. Spirax Sarco are always on hand to advise you about the best ways to manage your steam system and to help ensure you continue to reap these benefits. For more information about our steam trapping solutions, or any of our other solutions and services please visit spiraxsarco.com. spiraxsarco.com Operating Companies Sales Offices Distributors EMEA EMEA EMEA Belgium Netherlands Austria Algeria Iceland Mauritius Czech Republic Poland Hungary Bahrain Israel Morocco Denmark Portugal Jordan Bulgaria Ivory Coast Namibia Egypt Russia Kenya Cameroon Kuwait Nigeria Finland South Africa Romania Croatia Latvia Oman Spain Slovak Republic Cyprus Lebanon Qatar Germany Sweden Ukraine Ethiopia Lithuania Saudi Arabia Ireland Switzerland Estonia Madagascar Slovenia Turkey Ghana Malawi Sudan Greece Malta * France * Italy Middle East * UK Norway Hong Kong Kazakhstan Americas Vietnam * Argentina * Brazil * Mexico Canada Peru Chile Asia Pacific Colombia * USA Asia Pacific * Australia New Zealand China Philippines India Singapore Indonesia South Korea Japan Taiwan Malaysia Thailand Americas Bolivia Guatemala Panama Costa Rica Honduras Paraguay Dominican Republic Jamaica Trinidad and Tobago Ecuador Netherland Antilles Uruguay El Salvador Nicaragua Asia Pacific Bangladesh Fiji Cambodia Myanmar Pakistan * Manufacturing sites Spirax-Sarco Limited, Charlton House, Cheltenham, Gloucestershire, GL53 8ER, UK T +44 (0)1242 521361 F +44 (0)1242 573342 E enquiries@uk.spiraxsarco.com SB-GST-33 ST Issue 4 Spirax-Sarco ensures that it is fully compliant with all United Nations, European Union and U.S. sanctions in relation to the supply of its products and services. In relation to the manufacture of our products, we ensure we do not use conflict minerals. © Copyright 2015 Spirax Sarco is a registered trademark of Spirax-Sarco Limited